Eduardus Budi Nursanto, Ph.

D
Dr. Dita Floresyona

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Class rule
1. No communication devices (except if instructed)
2. Tolerance 15 minutes
3. Drinking water is okay
4. Going to toilette is okay
5. Taking slide picture is okay

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Syllabus
I. Materials Science and Engineering
a. Introduction of materials science and engineering
b. Atomic structure & bonding interactions
c. Crystal structure properties
d. Imperfection in solids
e. Diffusion
f. Mechanical properties
g. Dislocation & strengthening mechanism
h. Phase diagram

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Syllabus
II. Corrosion Science
a. Introduction to corrosion
b. Corrosion thermodynamics
c. Corrosion kinetics
d. Form of corrosion
e. Corrosion Testing Monitoring
f. Corrosion prevention and control
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References
1.Callister W.D., Material Science and Engineering: An Introduction, 7th
edition.
2.Smith, W. F. and J. Hashemi, Principles of Materials Science and
Engineering, 4th edition, McGraw-Hill Book Company, New York, 2006.

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Grading
• Homework: 30%
• Quiz: 10%
• Mid exam: 30%
• Final exam: 30%

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7
Why we need to study materials science
1. Chemical engineers should understand about the materials that
they choose during design of chemical unit process (choosing
materials, materials properties, corrosion, etc)
2. Some of chemical engineers dealing with large scale production of
materials

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 Point 1

Remember:
SAFETY FIRST

Fracture on tubular reactor Corrosion on vessel

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Point 1
Choosing materials for your unit
Is it need to
1. Corrosion resistant
2. Have ability for high pressure and high temperature
3. Cost

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Point 1
Corrosion Resistant Metals
1. Stainless steel 304/316
304 : Fe, Ni, Cr, C meanwhile 316: Fe, Ni, Cr, Mo, C
SS 316: marine grade steel
2. Aluminum alloy: light weight
3. Bronze, Brass & Copper: usually for catalyst
4. Galvanized steel: usually iron coated with Zn

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Point 2
DuPont is famous for the Teflon

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Point 2
Stainless steel production
Role of chemical engineer:
1. Process engineer
2. Process/product developer
3. Quality assurance

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Materials Science and Engineering

• It all about the raw materials and how they are processed
• That is why we call it materials ENGINEERING
• Minor differences in Raw materials or processing
parameters can mean major changes in the performance
of the final material or product

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Materials Science and Engineering
• Materials Science
– The discipline of investigating the relationships that exist between the structures
and properties of materials.
• Materials Engineering
– The discipline of designing or engineering the structure of a material to produce
a predetermined set of properties based on established structure-property
correlation.
• Four Major Components of Material Science and Engineering:
– Processing of Materials
– Structure of Materials
– Properties of Materials
– Performance of Materials

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And Remember: Materials “Drive” our Society!
• Ages of “Man” we survive based on the materials we control
– Stone Age – naturally occurring materials
• Special rocks, skins, wood
– Bronze Age
• Casting and forging
– Iron Age
• High Temperature furnaces
– Steel Age
• High Strength Alloys
– Non-Ferrous and Polymer Age
• Aluminum, Titanium and Nickel (superalloys) – aerospace
• Silicon – Information technology
• Plastics and Composites – food preservation, housing, aerospace and higher
speeds
– Exotic Materials Age?
• Nano-Material and bio-Materials – they are coming and then …
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And Formula One – the future of automotive is …
http://www.autofieldguide.com/articles/050701.html

From Ferrous material evolve into

non-ferrous material (alloy, carbon,
etc)

Toyota racing team has 100 alloy

type in their R&D Division

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 Doing Materials!
• Engineered Materials are a function of:
– Raw Materials Elemental Control
– Processing History
• Our Role in Engineering Materials then is to understand the application and specify the
appropriate material to do the job as a function of:
– Strength: yield and ultimate
– Ductility, flexibility
– Weight/density
– Working Environment
– Cost: Lifecycle expenses, Environmental impact*

* Economic and Environmental Factors often are the

most important when making the final decision!
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Example of Materials Engineering Work – Hip Implant

• With age or certain illnesses joints deteriorate.

Particularly those with large loads (such as hip).

Adapted from Fig. 22.25, Callister 7e.

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Example – Hip Implant
• Requirements
– mechanical strength
(many cycles)
– good lubricity
– biocompatibility

Adapted from Fig. 22.24, Callister 7e.

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Example – Hip Implant

Adapted from Fig. 22.24, Callister 7e.

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 Solution – Hip Implant
Acetabular
• Key Problems to Cup and
overcome: Liner

– fixation agent to hold Ball

acetabular cup
– cup lubrication material
– femoral stem – fixing agent
(“glue”)
– must avoid any debris in cup
– Must hold up in body
chemistry Femoral
– Must be strong yet flexible Stem

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Introduction
• List the Major Types of MATERIALS That You
Know:
– METALS
– CERAMICS
– POLYMERS
– COMPOSITES
– ADVANCED MATERIALS

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Introduction , continued

• Metals • Polymers
– Steel, Cast Iron, – Plastics, Wood, Cotton
Aluminum, Copper, (rayon, nylon), “glue”
Titanium, many others • Composites
• Ceramics – Glass Fiber-reinforced
– Glass, Concrete, Brick, polymers, Carbon Fiber-
Alumina, Zirconia, SiN, reinforced polymers,
SiC Metal Matrix
Composites, etc.

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Thoughts about these “fundamental”Materials
• Metals:
– Strong, ductile
– high thermal & electrical conductivity
– opaque, reflective.

• Polymers/plastics: Covalent bonding  sharing of e’s

– Soft, ductile, low strength, low density
– thermal & electrical insulators
– Optically translucent or transparent.

• Ceramics: ionic bonding (refractory) – compounds of metallic & non-

metallic elements (oxides, carbides, nitrides, sulfides)
– Brittle, glassy, elastic
– non-conducting (insulators)

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 The Materials Selection Process

1. Pick Application Determine required Properties

Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.
2. Properties Identify candidate Material(s)
Material: structure, composition.

3. Material Identify required Processing

Processing: changes structure and overall shape
ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

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 But:

Properties depend on Structure (d)

(strength or hardness)
600
Hardness (BHN)

30 m
500 (c)
400 (b)
(a)
4 m
300
30 m
200 30 m

100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)

And: Processing can change structure! (see

above structure vs Cooling Rate)
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 Another Example: Rolling of Steel

Yield strength (YS) is defined

as the maximum stress that a
solid material can withstand
when it is deformed within its
elastic limit. Ultimate strength
(UTS) is defined as the
maximum stress that a solid
material can withstand before
 At h1, L1 At h2, L2
 its failure.
 low UTS  high UTS
 low YS  high YS
 high ductility  low ductility
 round grains  elongated grains

Structure determines Properties but Processing determines

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Structure!
Optical Properties of Ceramic are controlled by
“Grain Structure”

SINGLE
CRYSTAL POLYCRYSTAL

POLYCRYSTAL
+ PORES

Figure 1.2 –Alumina(Al2O3)–single crystalandpolycrystal

Grain Structure is a function of

“Solidification” processing! 30
Electrical Properties (of Copper):
6
5
Electrical Resistivity of
4 Copper is affected by:
Resistivity, 
(10-8 Ohm-m)

3 • Contaminate level
• Degree of deformation
2
• Operating temperature
1
0
-200 -100 0 T
Adapted from Fig. 18.8, Callister 7e.
(Fig. 18.8 adapted from: J.O. Linde, (°C)
Ann Physik 5, 219 (1932); and
C.A. Wert and R.M. Thomson,
Physics of Solids, 2nd edition,
McGraw-Hill Company, New York,
1970.)

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 THERMAL Properties

• Space Shuttle Tiles: • Thermal Conductivity

--Silica fiber insulation of Copper: --It decreases when you
offers low heat conduction. add zinc!

400

Thermal Conductivity
300

(W/m-K)
Adapted from
Fig. 19.4W, 200
Callister 6e.
100
(Courtesy of
Lockheed 0
Aerospace 0 10 20 30 40
Composition (wt% Zinc)
Ceramics
Systems, Adapted from Fig. 19.4, Callister 7e.
Sunnyvale, CA) (Fig. 19.4 is adapted from Metals Handbook: Properties
(Note: "W" and Selection: Nonferrous alloys and Pure Metals, Vol.
denotes fig. 2, 9th ed., H. Baker, (Managing Editor), American
is on CD-ROM.) Society for Metals, 1979, p. 315.)
100m 32
 MAGNETIC Properties
• Magnetic Permeability
• Magnetic Storage: vs. Composition:
--Recording medium --Adding 3 atomic % Si makes Fe a
is magnetized by
better recording medium!
recording head.
Fe+3%Si

Magnetization
Fe

Magnetic Field

Adapted from C.R. Barrett, W.D. Nix,and

Fig. 20.23, Callister 7e. A.S. Tetelman, The Principles of
Engineering Materials, Fig. 1-7(a), p. 9,
(Fig. 20.23 is from J.U. Lemke, MRS Bulletin, 1973. Electronically reproduced
Vol. XV, No. 3, p. 31, 1990.) by permission of Pearson Education,Inc.,
Upper Saddle River, New Jersey. 33
DETERIORATIVE Properties
• Heat treatment: slows
• Stress & Saltwater... crack speed in salt water!
--causes cracks! 10-8 “as-is”
“held at

crack speed (m/s)

160ºC for 1 hr
before testing”
10-10 Alloy 7178 tested in
saturated aqueous NaCl
solution at 23ºC

increasing load
Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and Fracture Mechanics of
Engineering Materials" (4th ed.), p. 505, John Wiley and Sons, 1996. (Original source:
Markus O. Speidel, Brown Boveri Co.)

4 m
--material:
7150-T651 Al
"alloy"
Adapted from chapter-opening photograph,
Chapter 17, Callister 7e. (Zn,Cu,Mg,Zr)
(from Marine Corrosion, Causes, and Adapted from Fig. 11.26,
Prevention, John Wiley and Sons, Inc., 1975.) Callister 7e. (Fig. 11.26 provided courtesy of G.H.
Narayanan and A.G. Miller, Boeing Commercial
Airplane Company.) 34
Course Goal is to make you aware of the importance of Material Selection by:

• Using the right material for the job. one that Is most
economical and “Greenest” when life usage is
considered
• Understanding the relation between properties,
structure, and processing.
• Recognizing new design opportunities offered by
materials selection.

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